Suzuki LT-A750XP/Z Supplementary Service Manual

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DIC 179

3 mm

LT-A750XP/Z

Printed in U.S.A.

K9

9 9 5 0 1 - 4 7 0 5 0 - 0 3 E

LT-A750XP/Z

SUPPLEMENTARY SERVICE MANUAL

USE THIS MANUAL WITH:

LT-A750X/Z SERVICE MANUAL (99500-47021-03E)

LT-A750XP/ZK9 Supply 99501-47050-03E Cover 23 for PS printing (Back: 3 mm) 5/1

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FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI LT-A750X/Z SERVICE MANUAL.

It has been prepared exclusively for the following applicable model.

Applicable model:

LT-A750XK9

This supplementary service manual describes only service information which differ from that of the main man-

ual. Therefore, whenever servicing the above applicable model, consult this supplement first. And for any sec-

tion, item or description not found in this supplement, refer to the main manual below.

Main Manual:

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use

this section as well as other sections to use as a guide for proper inspection and service.

This manual will help you know the vehicle better so that you can assure your customers of fast and reliable ser-

vice.

Manual Name Manual No.

LT-A750X/ZK9 SERVICE MANUAL 99500-47021-03E

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-

cations have been made since then, differences may exist between the content of this manual and the

actual vehicle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. They

may not represent the actual vehicle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for

servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized

SUZUKI motorcycle dealer to help you.

WARNING

!

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to

properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider.

Prepared by

March, 2009

Part No. 99501-47050-03E

Printed in U.S.A.

132

00

0

1

2

3

4

5

6

9

Precautions............................................................... 00-i

Precautions ............................................................ 00-1

General Information ................................................... 0-i

General Information ............................................... 0A-1

Maintenance and Lubrication ................................. 0B-1

Service Data...........................................................0C-1

Engine ......................................................................... 1-i

Precautions ............................................................... 1-*

Engine General Information and Diagnosis ............1A-*

Emission Control Devices .......................................1B-*

Engine Electrical Devices....................................... 1C-*

Engine Mechanical................................................. 1D-*

Engine Lubrication System .....................................1E-*

Engine Cooling System...........................................1F-*

Fuel System ........................................................... 1G-*

Ignition System....................................................... 1H-*

Starting System....................................................... 1I-1

Charging System.....................................................1J-1

Exhaust System ......................................................1K-*

Suspension................................................................. 2-*

Precautions ............................................................... 2-*

Suspension General Diagnosis...............................2A-*

Front Suspension ....................................................2B-*

Rear Suspension.................................................... 2C-*

Wheels and Tires ................................................... 2D-*

Driveline / Axle ........................................................... 3-i

Precautions ............................................................... 3-*

Drive Chain / Drive Train / Drive Shaft ................... 3A-1

Differential ...............................................................3B-*

Transfer.................................................................. 3C-*

Propeller Shafts...................................................... 3D-*

Brake ........................................................................... 4-i

Precautions ............................................................... 4-*

Brake Control System and Diagnosis ....................4A-1

Front Brakes............................................................4B-*

Rear Brakes ........................................................... 4C-*

Parking Brake......................................................... 4D-*

Transmission / Transaxle .......................................... 5-*

Precautions ............................................................... 5-*

Automatic Transmission..........................................5A-*

Steering....................................................................... 6-i

Precautions .............................................................. 6-1

Steering General Diagnosis ................................... 6A-1

Steering / Handlebar .............................................. 6B-1

Power Assisted Steering System ...........................6C-1

Body and Accessories............................................... 9-i

Precautions ...............................................................9-*

Wiring Systems ......................................................9A-1

Lighting Systems.................................................... 9B-*

Combination Meter / Fuel Meter / Horn .................. 9C-*

Exterior Parts ......................................................... 9D-*

Body Structure .......................................................9E-1

TABLE OF CONTENTS

NOTE

For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same

sections of the service manual mentioned in the “FOREWORD” of this manual.

Table of Contents 00- i

00

Section 00

CONTENTS

Precautions

Precautions ...............................................00-1

Precautions........................................................... 00-1

Warning / Caution / Note...................................... 00-*

General Precautions ............................................00-*

Precautions for Electrical Circuit Service .............00-*

Precautions for EPS (LT-A750XP/ZK9) .............. 00-1

NOTE

For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual

mentioned in the “FOREWORD” of this manual.

00-1 Precautions:

Precauti ons

Precautions

Precautions for EPS (LT-A750XP/ZK9)

B931G40000004

EPS Wiring

• The EPS parts are connected to various lead wires.

The coupler and lead wire connections, as well as the

lead wire and wire harness routings must be done

correctly. Make sure that the proper clamps are used

and positioned correctly.

NOTE

If all of the connections are not properly

connected, the EPS may not operate

correctly. For connector and coupler

precautions. Refer to “Precautions for

Electrical Circuit Service in related manual”.

EPS Control Unit / EPS Body Assembly

• Never allow dust or water to contact the EPS control

unit and EPS body assembly.

• Since each component is a high-precision part, great

care should be taken not to apply any service impacts

during removal and installation.

• The EPS control unit and EPS body assembly cannot

be disassembled. Replace the whole unit with a new

one.

I931H1000004-01

I931H1000003-02

I931H1000005-01

Table of Contents 0- i

0

Section 0

CONTENTS

General Information

General Information ................................ 0A-1

General Description .............................................0A-1

Symbols ...............................................................0A-*

Abbreviations .......................................................0A-*

SAE-to-Former SUZUKI Term .............................0A-*

Vehicle Side View ................................................0A-*

Vehicle Identification Number ..............................0A-*

Fuel and Oil Recommendation ............................0A-*

Engine Coolant Recommendation .......................0A-*

BREAK-IN Procedures.........................................0A-*

Country and Area Codes .....................................0A-*

Wire Color Symbols .............................................0A-*

Warning, Caution and Information Labels

Location .............................................................0A-*

Abbreviations (LT-A750XP/ZK9)......................... 0A-1

Vehicle Side View (LT-A750XP/ZK9).................. 0A-1

Country and Area Codes (LT-A750XP/ZK9)....... 0A-1

Warning, Caution and Information Labels

Location (LT-A750XP/ZK9)...............................0A-2

Component Location ........................................... 0A-*

Electrical Components Location ..........................0A-*

Specifications.......................................................0A-3

Specifications (LT-A750X/ZK8)............................0A-*

Specifications (LT-A750X/ZK9)............................0A-*

Specifications (LT-A750XP/ZK9) ........................0A-3

Special Tools and Equipment ............................. 0A-*

Special Tools and Equipment .............................0A-5

Special Tool ........................................................ 0A-5

Maintenance and Lubrication................. 0B-1

Precautions........................................................... 0B-*

Precautions for Maintenance ...............................0B-*

General Description ............................................. 0B-*

Recommended Fluids and Lubricants..................0B-*

Scheduled Maintenance ...................................... 0B-*

Periodic Maintenance Schedule Chart.................0B-*

Lubrication Points ................................................0B-*

Repair Instructions ..............................................0B-1

Air Cleaner Element Inspection and Cleaning .....0B-*

Exhaust Pipe Bolt and Muffler Bolt Inspection .....0B-*

Valve Clearance Inspection and Adjustment .......0B-*

Spark Plug Replacement .....................................0B-*

Spark Plug Inspection and Cleaning....................0B-*

Spark Arrester Cleaning.......................................0B-*

Fuel Line Inspection ............................................ 0B-*

Engine Oil and Filter Replacement ..................... 0B-*

Front Differential Gear Oil Inspection.................. 0B-*

Front Differential Gear Oil Replacement ............. 0B-*

Final Gear Oil Inspection..................................... 0B-*

Final Gear Oil Replacement................................ 0B-*

Throttle Cable Play Inspection and

Adjustment ........................................................ 0B-*

Throttle Body Inspection ..................................... 0B-*

Cooling System Inspection.................................. 0B-*

Drive V-belt Inspection and Replacement........... 0B-*

Drive Shaft Boots Inspection............................... 0B-*

Front Brake System Inspection ........................... 0B-*

Rear Brake Pedal / Rear Brake (Parking

Brake) Lever Inspection and Adjustment .......... 0B-*

Rear Brake Friction Plate Wear Limit

Inspection.......................................................... 0B-*

Tire Inspection..................................................... 0B-*

Steering System Inspection ................................ 0B-*

Toe Adjustment ................................................... 0B-*

Suspensions Inspection ...................................... 0B-*

Chassis Bolt and Nut Inspection ......................... 0B-*

Compression Pressure Check ............................ 0B-*

Oil Pressure Check ............................................. 0B-*

SDS Check.......................................................... 0B-*

Automatic Clutch Inspection................................ 0B-*

Air Cleaner Element Inspection and Cleaning

(LT-A750XP/ZK9)..............................................0B-1

Steering System Inspection (LT-A750XP/

ZK9) ..................................................................0B-1

Toe Adjustment (LT-A750XP/ZK9) .....................0B-2

Chassis Bolt and Nut Inspection (LT-A750XP/

ZK9) ..................................................................0B-3

Specifications.......................................................0B-4

Tightening Torque Specifications........................0B-4

Special Tools and Equipment ............................. 0B-*

Recommended Service Material ......................... 0B-*

Special Tool ........................................................ 0B-*

Service Data ............................................. 0C-1

Specifications.......................................................0C-1

Service Data........................................................ 0C-*

Tightening Torque List ........................................ 0C-*

Service Data (LT-A750XP/ZK9) ..........................0C-1

Tightening Torque List (LT-A750XP/ZK9)...........0C-7

NOTE

For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual

mentioned in the “FOREWORD” of this manual.

0A-1 General Information:

General Info rmation

General Information

General Description

Abbreviations (LT-A750XP/ZK9)

B931G40101012

NOTE

Please refer to the LT-A750XK9 (’09-model) service manual for other abbreviations which are not given

in this manual.

E:

EPS: Electronic Power Steering

Vehicle Side View (LT-A750XP/ZK9)

B931G40101013

NOTE

Difference between illustration and actual

motorcycles may exist depending on the

markets.

SUZUKI LT-A750XP (2009-model)

Right Side

Left Side

Country and Area Codes (LT-A750XP/ZK9)

B931G40101014

The following codes stand for the applicable country(-ies) and area(-s).

I931G3010001-01

I931G3010002-01

Code Country or Area Effective Frame No.

LT-A750XPK9 (P-17) Sweden

5SAAR41P97100001 –

LT-A750XPK9 (P-24) Australia

LT-A750XPK9 (P-28) Canada

LT-A750XPK9 (P-33) U.S.A.

LT-A750XPZK9 (P-17) Sweden

LT-A750XPZK9 (P-24) Australia

LT-A750XPZK9 (P-28) Canada

LT-A750XPZK9 (P-33) U.S.A.

General Information: 0A-2

Warning, Caution and Information Labels Location (LT-A750XP/ZK9)

B931G40101015

5

14

17, 18

11

9

6

3

7

8

10

12, 13

15, 16

4

1, 20, 21

22, 23

24

19

25

2, 26, 27

[A]

I931H1010010-03

1. Certification plate (English) For P-24, 33 15. Front carrier warning label (English) For P-24, 33

2. Information label (English) For P-33 16. Front carrier warning label (English/French) For P-17, 28

3. Gearshift label (English) For P-17, 24, 28, 33 17. Rear carrier warning label (English) For P-24, 33

4. Gearshift label (French) For P-28 18. Rear carrier warning label (English/French) For P-17, 28

5. Tire air pressure label (English) For P-17, 24, 28, 33 19. ICES Canada label (English/French) For P-28

6. Tire air pressure label and warning no-

passenger label (French)

For P-28

20. Compliance label (English)

For P-28

7. General warning & AGE, 16 label (English) For P-17, 24, 28, 33 21. I.D. plate (English) For P-17

8. General warning label (French) For P-28 22. Cooling fan label (English) For P-24, 33

9. Warning no-passenger label (English) For P-17, 24, 28, 33 23. Cooling fan label (English/French) For P-17, 28

10. AGE, 16 label (French) For P-28 24. Compliance label (English/French) For P-28

11. Manual notice label (English) For P-33 25. ANSI certification label (Right side of frame) For P-33

12. Max AMP caution label (English) For P-24, 33 26. Information label (English) For P-28

13. Max AMP caution label (English/French)

For P-17, 28

27. Information label (French)

(Right side of frame)

For P-28

14. Fuel caution label (English) For P-24 [A]: Left side of frame

0A-3 General Information:

Specifications

Specifications (LT-A750XP/ZK9)

B931G40107003

NOTE

These specifications are subject to change without notice.

Dimensions and curb mass

Engine

Drive train

Item Specification Remark

Overall length

2 115 mm (83.3 in) P-28, 33

2 165 mm (85.2 in) P-17, 24

Overall width

1 210 mm (47.6 in) P-28, 33

1 250 mm (49.2 in) P-17, 24

Overall height 1 285 mm (50.6 in)

Wheelbase 1 285 mm (50.6 in)

Ground clearance 260 mm (10.2 in)

Seat height 920 mm (36.2 in)

Curb mass

305 kg (672 lbs) P-28, 33

307 kg (677 lbs) P-17, 24

Front track 940 mm (37.0 in)

Rear track 920 mm (36.2 in)

Item Specification Remark

Type 4-stroke, liquid-cooled, DOHC

Number of cylinders 1

Bore 104.0 mm (4.094 in)

Stroke 85.0 mm (3.346 in)

Displacement 722 cm

3

(44.1 cu. in)

Compression ratio 10.0 : 1

Fuel system Fuel injection

Air cleaner Paper element

Starter system Electric starter

Lubrication system Wet sump

Idle speed 1 300 ± 100 r/min

Item Specification Remark

Clutch Wet shoe, automatic, centrifugal type

Transmission CVT (V-belt)

Transfer 2-speed forward with reverse

Gearshift

pattern

Transmission Automatic

Transfer L-H-N-R (Hand operated)

Automatic transmission ratio Variable change (2.763 – 0.78)

Secondary reduction ratio 2.158 (40/21 x 17/15)

Final reduction ratio

(Front & Rear)

3.600 (36/10)

Transfer gear

ratio

Low 2.562 (41/16)

High 1.240 (31/25)

Reverse 1.882 (32/17)

Drive system Shaft drive

General Information: 0A-4

Chassis

Electrical

Capacities

Item Specification Remark

Front suspension Independent, double wishbone, coil spring, oil damped

Rear suspension Independent, double wishbone, coil spring, oil damped

Front wheel travel 170.5 mm (6.7 in)

Rear wheel travel 195 mm (7.7 in)

Caster 3.3°

Trail 16.7 mm (0.66 in)

Toe-out 5 mm (0.20 in)

Camber –1.3°

Steering angle 46° (right & left)

Turning radius 3.1 m (10.2 ft)

Front brake Disc brake, twin

Rear brake Sealed oil-bathed multi-disc

Front tire size AT25 x 8-12, tubeless

Rear tire size AT25 x 10-12, tubeless

Item Specification Remark

Ignition type Electronic ignition (CDI)

Ignition timing 7° B.T.D.C. at 1 300 r/min

Spark plug NGK CR6E or DENSO U20ESR-N

Battery 12 V 64.8 kC (18 Ah)/10 HR

Generator Three-phase A.C. generator

Main fuse 30 A

Fuse 10/10/10/10/15/15 A

EPS fuse 40 A

Headlight 12 V 35/35 W x 2

Auxiliary light 12 V 35/35 W

Brake light/Taillight 12 V 21/5 W

Reversing light 12 V 21 W P-17

Speedometer light LED

Neutral indicator light LED

High beam indicator light LED P-17

Coolant temperature/FI

indicator light

LED

Reverse indicator light LED

Diff-lock indicator light LED

EPS indicator light LED

Item Specification Remark

Fuel tank 17.5 L (4.6/3.8 US/lmp gal)

Engine oil

Oil change 2 300 ml (2.4/2.0 US/lmp qt)

With filter

change

2 500 ml (2.6/2.2 US/lmp qt)

Overhaul 3 000 ml (3.2/2.6 US/lmp qt)

Differential gear oil 500 ml (16.9/17.6 US/lmp oz)

Final gear oil 770 ml (26.0/27.1 US/lmp oz)

Coolant 2.5 L (2.6/2.2 US/lmp qt)

0A-5 General Information:

Special Tools and Equipment

Special Tool

B931G40108002

09900–06107

Snap ring remover

(Open type)

09900–20102

Vernier calipers (200

mm)

09900–25008

Multi circuit tester set

09900–25009

Needle-point probe

set

09904–41010

SUZUKI Diagnostic

system set

09924–84521

Bearing installer set

09930–30721

Rotor remover

09930–44530

Rotor holder

09930–82710

Mode select switch

09930–82720

Mode selection switch

09942–72410

Tie-rod end remover

09942–83110

Clip remover

09944–36011

Steering wheel

remover

99565–01010–020

CD-ROM Ver.20

Maintenance and Lubrication: 0B-1

General Info rmation

Maintenance and Lubrication

Repair Instructions

Air Cleaner Element Inspection and Cleaning

(LT-A750XP/ZK9)

B931G40206030

Clean element

Every 1 000 km (600 miles, 3 months)

If the air cleaner is clogged with dust, intake resistance

will be increased, with a resultant decrease in power

output and an increase in fuel consumption. Check and

clean the air cleaner element in the following manner.

CAUTION

!

• If driving under dusty conditions, clean the

air cleaner element more frequently. The

surest way to accelerate engine wear is to

operate the engine without the element or

to use a torn element. Make sure that the

air cleaner is in good condition at all times.

Life of the engine depends largely on this

component.

• Inspect the air cleaner element for tears. A

torn element must be replaced.

1) Remove the air cleaner element. Refer to “Air

Cleaner Element Removal and Installation in Section

1D in related manual”.

2) Separate the polyurethane from element.

3) Fill a wash pan of a proper size with a non-

flammable cleaning solvent. Immerse the air cleaner

element in the cleaning solvent and wash it.

4) Press the air cleaner element between the palms of

both hands to remove the excess solvent: do not

twist or wring the element or it will tear.

5) Immerse the element in motor oil, and then squeeze

out the excess oil leaving the element slightly wet.

6) After cleaning the air cleaner element, reinstall the

removed parts.

7) Drain water from the air cleaner box by removing the

drain plug.

8) Reinstall the drain plug.

Steering System Inspection (LT-A750XP/ZK9)

B931G40206031

Inspect steering system

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

Steering should be adjusted properly for smooth turning

of handlebars and safe running.

1) Place the vehicle on level ground.

2) Make sure the tire pressure for right and left tires in

the same and set to the proper specification.

3) Set the front wheels in the straight position.

4) Place a load of 75 kg (165 lbs) on the seat.

I831G1020002-01

“A”: Non-flammable cleaning solvent

“B”: Motor oil SAE #30 or SAE 10W-40

“A”

“B”

I931G3020009-01

I831G1020004-01

0B-2 Maintenance and Lubrication:

5) Measure the distances (“A” and “B”) between the

front wheels. Subtract the measurement of “A” from

that of “B” to find the toe-out. If the toe-out is not

within specification, adjust the tie-rod to the right or

left until the toe-out is within the specified range.

Toe-out (“B” – “A”)

Standard: 5 ± 4 mm (0.20 ± 0.16 in)

If the toe-out is out of specification, bring it into the

specified range. Refer to “Toe Adjustment (LT-A750XP/

ZK9) (Page 0B-2)”.

Toe Adjustment (LT-A750XP/ZK9)

B931G40206032

Adjust the toe-out as follows:

1) Loosen the lock-nuts (1), (2) on each tie-rod.

CAUTION

!

• The lock-nuts (2) have left-hand threads.

• When loosening and tightening the lock-

nuts, hold the tie-rod end with a open end

wrench.

NOTE

Hold the concave part “a” of tie-rod with a

wrench.

2) Temporarily tighten the four lock-nuts.

3) Check that the distances “C” and “D” are equal, as

shown. If the distances are not equal, adjust the tie-

rod to the right or left until the toe-out is within

specification. Check the toe-out again by measuring

distances “A” and “B”.

4) If the toe-out is not within specification, repeat the

adjustment as above until the proper toe-out is

obtained and distances “C” and “D” become equal.

5) After adjustment has been made, tighten the four

lock-nuts to the specified torque.

Tightening torque

Tie-rod lock-nut (a): 29 N·m (2.9 kgf-m, 21.0 lbf-

ft)

I931H1020057-01

FWD

“A”

“B”

I831G1020059-04

2

1

“a”

FWD

I931H1020079-02

“C”

Right angle

(90

°

)

FWD

“A”

“B”

“D”

I831G1020088-04

(a)

I831G1020089-01

Maintenance and Lubrication: 0B-3

Chassis Bolt and Nut Inspection (LT-A750XP/

ZK9)

B931G40206033

Tighten chassis bolt and nut

Initially at 200 km (100 miles, 1 month) and every 1

000 km (600 miles, 3 months) thereafter

Check that all chassis bolts and nuts are tightened to

their specified torque.

1 EPS body assembly mounting bolt (Upper) 26 N⋅m (2.6 kgf-m,

19.0 lbf-ft)

2 EPS body assembly mounting nut (Lower) 28 N⋅m (2.8 kgf-m,

20.0 lbf-ft)

3 Steering shaft bolt 26 N⋅m (2.6 kgf-m, 19.0 lbf-ft)

(a)

1

I931G3020001-01

(b)

2

I931G3020002-01

(a)

3

I931G3020003-01

4 Steering shaft upper nut 120 N⋅m (12.0 kgf-m, 87.0 lbf-ft)

5 Tie-rod lock-nut 29 N⋅m (2.9 kgf-m, 21.0 lbf-ft)

6 Rear stabilizer joint nut 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft)

7 Rear brake pedal screw 4.5 N⋅m (0.45 kgf-m, 3.0 lbf-ft)

(c)

4

I931G3020004-02

(d)

5

(d)

5

I931G3020005-02

(e)

6

(e)

6

I931G3020007-02

(f)

7

I931G3020008-01

0B-4 Maintenance and Lubrication:

Specifications

Tightening Torque Specifications

B931G40207001

NOTE

The specified tightening torque is described in the following.

“Chassis Bolt and Nut Inspection (LT-A750XP/ZK9) (Page 0B-3)”

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in

Section 0C (Page 0C-7)”.

Fastening part

Tightening torque

Note

N⋅m kgf-m lbf-ft

Tie-rod lock-nut 29 2.9 21.0 )(Page 0B-2)

Service Data: 0C-1

General Info rmation

Service Data

Specifications

Service Data (LT-A750XP/ZK9)

B931G40307003

Valve + Valve Guide

Unit: mm (in)

Camshaft + Cylinder Head

Unit: mm (in)

Item Standard Limit

Valve diam.

IN. 36.0 (1.42) —

EX. 33.0 (1.30) —

Tappet clearance (When cold)

IN. 0.10 – 0.20 (0.004 – 0.008) —

EX. 0.20 – 0.30 (0.008 – 0.012) —

Valve guide to valve stem clearance

IN. 0.010 – 0.037 (0.0004 – 0.0015) —

EX. 0.030 – 0.057 (0.0012 – 0.0022) —

Valve guide I.D. IN. & EX. 5.500 – 5.512 (0.2165 – 0.2170) —

Valve stem O.D.

IN. 5.475 – 5.490 (0.2156 – 0.2161) —

EX. 5.455 – 5.470 (0.2148 – 0.2154) —

Valve stem deflection IN. & EX. — 0.35 (0.014)

Valve stem runout IN. & EX. — 0.05 (0.002)

Valve head thickness IN. & EX. — 0.5 (0.02)

Valve seat width IN. & EX. 0.9 – 1.1 (0.035 – 0.043) —

Valve head radial runout IN. & EX. — 0.03 (0.001)

Valve spring free length IN. & EX. — 46.1 (1.81)

Valve spring tension IN. & EX.

182 – 210 N (18.6 – 21.4 kgf, 41.0 – 47.2 lbs)

at length 36.35 mm (1.43 in)

—

Item Standard Limit

Cam height

IN. 36.330 – 36.380 (1.4303 – 1.4323) 36.030 (1.4185)

EX. 35.300 – 35.350 (1.3898 – 1.3917) 35.000 (1.3780)

Camshaft journal oil clearance IN. & EX. 0.019 – 0.053 (0.0007 – 0.0021) 0.150 (0.0059)

Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 (0.8666 – 0.8671) —

Camshaft journal O.D. IN. & EX. 21.972 – 21.993 (0.8650 – 0.8659) —

Camshaft runout IN. & EX. — 0.10 (0.004)

Cylinder head distortion — 0.05 (0.002)

Cam drive idle gear/sprocket thrust

clearance

0.15 – 0.27 (0.006 – 0.011) —

0C-2 Service Data:

Cylinder + Piston + Piston Ring

Unit: mm (in)

Conrod + Crankshaft

Unit: mm (in)

Oil Pump

Clutch

Unit: mm (in)

Item Standard Limit

Compression pressure

(Automatic-decomp. actuated)

Approx. 1 000 kPa (10.0 kgf/cm

2

, 142 psi) —

Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047)

Cylinder bore 104.000 – 104.015 (4.0945 – 4.0951)

Nicks or

Scratches

Piston diam.

103.965 – 103.980 (4.0931 – 4.0937)

Measure at 15 mm (0.6 in) from the skirt end.

103.880 (4.0898)

Cylinder distortion — 0.05 (0.002)

Piston ring free end gap

1st R Approx. 13.1 (0.52) 10.5 (0.41)

2nd RN Approx. 14.6 (0.57) 11.7 (0.46)

Piston ring end gap

1st R 0.10 – 0.25 (0.004 – 0.010) 0.50 (0.020)

2nd RN 0.10 – 0.25 (0.004 – 0.010) 0.50 (0.020)

Piston ring-to-groove clearance

1st — 0.180 (0.0071)

2nd — 0.150 (0.0059)

Piston ring groove width

1st

0.83 – 0.85 (0.0327 – 0.0335)

1.30 – 1.32 (0.0512 – 0.0520)

—

2nd 1.01 – 1.03 (0.0398 – 0.0406) —

Oil 2.01 – 2.03 (0.0791 – 0.0799) —

Piston ring thickness

1st

0.76 – 0.81 (0.0299 – 0.0319) —

1.08 – 1.10 (0.0425 – 0.0433) —

2nd 0.97 – 0.99 (0.0382 – 0.0390) —

Piston pin bore I.D. 23.002 – 23.008 (0.9056 – 0.9058) 23.030 (0.9067)

Piston pin O.D. 22.992 – 23.000 (0.9052 – 0.9055) 22.980 (0.9047)

Item Standard Limit

Conrod small end I.D. 23.006 – 23.014 (0.9057 – 0.9061) 23.040 (0.9071)

Conrod deflection — 3.0 (0.12)

Conrod big end side clearance 0.10 – 0.75 (0.004 – 0.030) 1.0 (0.04)

Conrod big end width 24.95 – 25.00 (0.982 – 0.984) —

Crank web to web width 72.9 – 73.1 (2.87 – 2.88) —

Crankshaft runout — 0.08 (0.003)

Item Standard Limit

Oil pressure (at 60 °C, 140 °F)

140 – 180 kPa

(1.4 – 1.8 kgf/cm

2

, 20 – 26 psi)

at 3 000 r/min

—

Item Standard Limit

Clutch wheel I.D. 140.0 – 140.2 (5.512 – 5.520) 140.5 (5.53)

Clutch shoe —

No groove at any

part

Clutch engagement r/min 1 500 – 2 000 r/min —

Clutch lock-up r/min 3 500 – 4 000 r/min —

Service Data: 0C-3

Drive Train

Unit: mm (in) Except ratio

Thermostat + Radiator + Fan + Coolant

Item Standard Limit

Automatic transmission ratio Variable change (2.763 – 0.780) —

Secondary reduction ratio 2.158 (40/21 x 17/15) —

Final reduction ratio

Front 3.600 (36/10) —

Rear 3.600 (36/10) —

Transfer gear ratio

Low 2.562 (41/16) —

High 1.240 (31/25) —

Reverse 1.882 (32/17) —

Drive V-belt width 34.3 (1.35) 33.3 (1.31)

Movable driven face spring free

length

160.0 (6.30) 152.0 (6.00)

Shift fork to groove

clearance

Low 0.10 – 0.30 (0.0040 – 0.0120) 0.50 (0.020)

High 0.10 – 0.30 (0.0040 – 0.0120) 0.50 (0.020)

Reverse 0.10 – 0.30 (0.0040 – 0.0120) 0.50 (0.020)

Shift fork groove

width

Low 5.50 – 5.60 (0.217 – 0.220) —

High 5.50 – 5.60 (0.217 – 0.220) —

Reverse 5.50 – 5.60 (0.217 – 0.220) —

Shift fork thickness

Low 5.30 – 5.40 (0.209 – 0.213) —

High 5.30 – 5.40 (0.209 – 0.213) —

Reverse 5.30 – 5.40 (0.209 – 0.213) —

Front/Rear output shaft bevel gear

backlash

0.03 – 0.15 (0.001 – 0.006) —

Front drive (differential) gear

backlash

0.05 – 0.10 (0.002 – 0.004) —

Rear drive (final)

gear backlash

Without gear

cover

specification

0.02 – 0.06 (0.0008 – 0.0024) —

Gear cover

assembled

specification

0.08 – 0.15 (0.0031 – 0.0059) —

Front differential gear oil type Hypoid gear oil SAE #90, API grade GL-5 —

Rear drive gear oil type Mobil 424 or equivalent gear oil —

Front differential gear oil capacity 500 ml (16.9/17.6 US/lmp oz) —

Final gear oil capacity 770 ml (26.0/27.1 US/lmp oz) —

Item Standard Note

Thermostat valve opening

temperature

Approx. 82 °C (180 °F)

Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F)

ECT sensor resistance

20 °C

(68 °F)

Approx. 2.45 kΩ

50 °C

(122 °F)

Approx. 0.811 kΩ

80 °C

(176 °F)

Approx. 0.318 kΩ

110 °C

(230 °F)

Approx. 0.142 kΩ

Radiator cap valve opening

pressure

110 – 140 kPa (1.1 – 1.4 kgf/cm

2

, 15.6 – 19.9 psi)

Cooling fan thermo-switch operating

temperature

OFF → ON Approx. 93 °C (199 °F)

ON → OFF Approx. 87 °C (189 °F)

Engine coolant type

Use an antifreeze/coolant compatible with aluminum

radiator, mixed with distilled water only, at the ratio of 50:50.

Engine coolant

Reservoir Approx. 250 ml (0.26/0.22 US/lmp qt)

Engine Approx. 2 200 ml (2.32/1.94 US/lmp qt)

0C-4 Service Data:

Injector + Fuel Pump + Fuel Pressure Regulator

FI Sensors + Secondary Throttle Valve Actuator

Throttle Body

Item Specification Note

Injector resistance 11 – 13 Ω at 20 °C (68 °F)

Fuel pump discharge amount 55.5 ml (1.88/1.95 US/lmp qt) and more/10 sec.

Fuel pressure regulator operating

set pressure

Approx. 294 kPa (2.9 kgf/cm

2

, 41 psi)

Item Specification Note

CKP sensor resistance 150 – 250 Ω

CKP sensor peak voltage 5.0 V and more When cranking

IAP sensor input voltage 4.5 – 5.5 V

IAP sensor output voltage Approx. 2.63 V at idle speed

TP sensor input voltage 4.5 – 5.5 V

TP sensor output voltage

Closed Approx. 1.1 V

Opened Approx. 4.3 V

ECT sensor input voltage 4.5 – 5.5 V

ECT sensor output voltage 0.15 – 4.85 V

ECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)

IAT sensor input voltage 4.5 – 5.5 V

IAT sensor output voltage 0.15 – 4.85 V

IAT sensor resistance Approx. 1.60 kΩ at 20 °C (68 °F)

TO sensor resistance 19 – 20 kΩ

TO sensor voltage

Normal 0.4 – 1.4 V

Leaning 3.7 – 4.4 V When leaning 65°

GP switch voltage 0.6 V and more From 1st to Top

Injector voltage Battery voltage

Ignition coil primary peak voltage 80 V and more When cranking

ISC valve resistance Approx. 31 kΩ at 20 °C (68 °F)

Item Specification

Bore size 42 mm

I.D. No. 31G0

Idle r/min 1 300 ± 100 r/min

Fast idle r/min 1 500 – 2 000 r/min (When cold engine)

Throttle cable play 3 – 5 mm (0.12 – 0.20 in)

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Suzuki LT-A750XP/Z Supplementary Service Manual

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